Footwear device

ABSTRACT

The disclosure provides a footwear device, a footwear assembly, a method for making the footwear device, and a method for making the footwear assembly that can reduce manufacturing costs and complexities.

CROSS-REFERENCE TO PRIOR APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application No. 61/535,134, filed Sep. 15, 2011, andtitled “FOOTWEAR DEVICE,” the disclosure of which is hereby expresslyincorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a footwear device, a footwearassembly, a method for making the footwear device, and a method formaking the footwear assembly.

BACKGROUND OF THE DISCLOSURE

Footwear comes in various types, styles, shapes and sizes. However,footwear generally includes certain common components, such as, forexample, an outsole and an upper. Various methodologies have beenemployed in attaching an upper to an outsole of a shoe. For example, itis known to sew an upper lip of an outsole to a shoe upper, as describedin U.S. Pat. No. 7,757,408. These attachment methodologies can be costlyin terms of time and complexity.

The disclosure provides a footwear device, a footwear assembly, a methodfor making the footwear device, and a method for making the footwearassembly that can reduce manufacturing costs and complexities.

SUMMARY OF THE DISCLOSURE

According to one aspect of the disclosure, a footwear device isdisclosed that may be implemented as an interface between an upperportion and a lower portion of footwear. The footwear device maycomprise a substantially L-shaped cross-section. The footwear device mayfurther include a substantially curved wall and at least onesubstantially planar wall. The footwear device may further comprise astitch that is configured, for example, longitudinally along thefootwear device. The footwear device may be made from a materialcomprising, for example, leather, plastic, rubber, silicone, metal, orany other material suitable for footwear.

According to another aspect of the disclosure, a footwear assembly isdisclosed. The footwear assembly comprises the upper portion, the lowerportions, and the footwear device.

According to a further aspect of the disclosure, a method for making thefootwear device is disclosed. The method comprises forming alongitudinal member from a material that may include, for example,rubber, synthetic rubber, leather (e.g., composition leather or patentleather), plastic (e.g., plastic sheeting or cellular plastic sheeting),textiles (both woven and non-woven), plaiting materials, neoprene, wood,cork, rubber, silicone, metal, or any other material suitable firfootwear. The longitudinal member may be formed to have a substantiallyL-shaped cross-section. The longitudinal member may be further formed toinclude a curved wall and a substantially planar wall.

The footwear device may comprise a stitch member that may be configured,for example, substantially longitudinally along the longitudinal member.The footwear device may further comprise a second stitch member that isconfigured, for example, substantially longitudinally along thelongitudinal member. The first stitch member may be fastened to thelongitudinal member by means of the second stitch member. The first andsecond stitch members may be made of a material comprising, for example,natural fibers (e.g., manila hemp, hemp, linen, cotton, coir, jute,sisal, silk, wool, or the like) or synthetic fibers (e.g., nylon, rayon,polypropylene, polyesters, polyethylene, aramids, polyaramids, or thelike). The first and second stitch members may each be braided.

According to a still further aspect of the disclosure, a method formaking the footwear assembly is disclosed. The method comprisesattaching a footwear device to a lower portion, and attaching an upperportion to the footwear device. The lower portion may comprise anoutsole. The process of attaching the footwear device to the lowerportion may comprise applying an adhesive to a section of the lowerportion and a section of the footwear device, and affixing the sectionof the footwear device to section of the lower portion. The process ofattaching the upper portion to the footwear device may comprise applyingan adhesive to another section of the footwear device and a section ofthe upper portion, and affixing the section of the dipper portion to thesection of the footwear device. The footwear assembly may comprise, forexample, a shoe, a sneaker, a boot, a slipper, or the like.

Additional features, advantages, and embodiments of the disclosure maybe set forth or apparent from consideration of the detailed descriptionand drawings. Moreover, it is to be understood that the foregoingsummary of the disclosure and the following detailed description anddrawings are exemplary and intended to provide further explanationwithout limiting the scope of the disclosure as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the disclosure, are incorporated in and constitute apart of this specification, illustrate embodiments of the disclosure andtogether with the detailed description serve to explain the principlesof the disclosure. No attempt is made to show structural details of thedisclosure in more detail than may be necessary for a fundamentalunderstanding of the disclosure and the various ways in which it may bepracticed. In the drawings:

FIG. 1 shows an example of a footwear device according to the instantdisclosure;

FIG. 2 shows a cross-section view of the footwear device of FIG. 1;

FIG. 3 shows a side view of an example of a lower portion of a footwearassembly;

FIG. 4 shows a side view of the footwear device of FIG. 1 attached tothe lower portion of the footwear assembly of FIG. 3;

FIGS. 5-7 show various steps of a process for manufacturing a footwearassembly; and

FIG. 8 shows an example of a footwear assembly comprising the lowerportion and a footwear device according to the instant disclosure.

The present disclosure is further described in the detailed descriptionthat follows.

DETAILED DESCRIPTION OF THE DISCLOSURE

The disclosure and the various features and advantageous details thereofare explained more fully with reference to the non-limiting embodimentsand examples that are described and/or illustrated in the accompanyingdrawings and detailed in the following description. It should be notedthat the features illustrated in the drawings are not necessarily drawnto scale, and features of one embodiment may be employed with otherembodiments, even if not explicitly stated herein. Descriptions ofwell-known components and processing techniques may be omitted so as tonot unnecessarily obscure the embodiments of the disclosure. Theexamples used herein are intended merely to facilitate an understandingof ways in which the disclosure may be practiced and to further enablethose of skill in the art to practice the embodiments of the disclosure.Accordingly, the examples and embodiments herein should not be construedas limiting the scope of the disclosure. Moreover, it is noted that likereference numerals represent similar parts throughout the several viewsof the drawings.

The terms “including,” “comprising,” and variations thereof as used inthis disclosure, mean “including, but not limited to,” unless expresslyspecified otherwise.

The terms “a,” “an,” and “the,” as used in this disclosure, means “oneor more,” unless expressly specified otherwise.

Although process steps, method steps, algorithms, or the like, may bedescribed in a sequential order, such processes, methods and algorithmsmay be configured to work in alternate orders. In other words, anysequence or order of steps that may be described does not necessarilyindicate a requirement that the steps be performed in that order. Thesteps of the processes, methods or algorithms described herein may beperformed in any order practical. Further, some steps may be performedsimultaneously.

When a single device or article is described herein, it will be readilyapparent that more than one device or article may be used in place of asingle device or article. Similarly, where more than one device orarticle is described herein, it will be readily apparent that a singledevice or article may be used in place of the more than one device orarticle. The functionality or the features of a device may bealternatively embodied by one or more other devices which are notexplicitly described as having such functionality or features.

FIG. 1 shows an example of a footwear device 100, according to theprinciples of the disclosure. The footwear device 100 may be implementedas an interface between an upper portion (not shown) and a lower portion(not shown) of a footwear assembly. A non-limiting example of a footwearassembly is shown in FIG. 8. The footwear device 100 comprises asubstantially L-shaped cross-section 120. The footwear device 100 mayinclude a substantially curved wall 140 and a pair of walls 150, 155.

The substantially curved wall 140 may include a substantially uniformand smooth surface (not shown), or a surface that is configured tosubstantially match a shape of a part of the upper (and/or the lower)portion of a footwear assembly, so that it may snuggly attach to theupper (and/or lower) portion of the footwear assembly.

The walls 150, 155 may be substantially planar. The wall 150 may includea surface that is configured to substantially match a shape of a part ofthe lower portion of a footwear assembly, so that it may snuggly attachto the lower portion of the footwear assembly. The wall 155 may have anyshape desired for aesthetic appeal, including, e.g., a substantiallyplanar surface, a curved surface, a surface comprising patterns, and thelike.

According to an aspect of the disclosure, the walls 150, 155 may besubstantially perpendicular to each other (as seen, e.g., in FIG. 2).However, the walls 150, 155 may have any angle with respect to eachother including, for example, less than about 90° or more than about90°.

The term “substantially planar wall,” as used in this disclosure, refersto a wall that lies mostly, or completely, within one plane. Typically,about 50% to about 100%, about 60% to about 100%, or about 80% to about100% of the wall lies within one plane.

The footwear device 100 may further comprise a stitch 130 that isconfigured, for example, longitudinally along the footwear device 100.The footwear device 100 may include a channel 135 along the longitudinaldirection. The stitch 130 may be provided along the entire (or a part ofthe) length of the channel 135.

The footwear device 100 may be made from a material comprising, forexample, rubber, synthetic rubber, silicone, metal silicone, leather(e.g., composition leather or patent leather), plastic (e.g., plasticsheeting or cellular plastic sheeting), textiles (both woven andnon-woven), plaiting materials, neoprene, wood, cork, rubber, or anyother material suitable for footwear.

FIGS. 2-4 show various views of the foot wear device 100 and/or a lowerportion 200 of footwear. In particular, FIG. 2 shows a cross-sectionview of the footwear device 100; FIG. 3 shows a side view of the lowerportion 200 that may be used in a footwear assembly; and FIG. 4 shows aside view of the footwear device 100 attached to the lower portion 200.As seen in the illustrations, the lower portion 200 may include anoutsole 210, an interface section 220, and a bottom 230.

According to a further aspect of the disclosure, a method for making thefootwear device is disclosed. The method comprises forming alongitudinal member 110 from a material that may include, for example,leather, plastic, rubber, silicone, metal, or any other materialsuitable for footwear. The longitudinal member 110 may be formed to havea substantially L-shaped cross-section. The longitudinal member 110 maybe further formed to include a curved wall and a substantially planarwall.

The footwear device may comprise a first stitch member (not shown) thatis configured, for example, substantially longitudinally along thelongitudinal direction of the footwear device 100. The footwear device100 may further comprise a second stitch member (not shown) that isconfigured, for example, substantially longitudinally along thelongitudinal member 110. The first stitch member may be fastened to thelongitudinal member 110 by means of the second stitch member. In thisregard, the second stitch member may be pierced through the longitudinalmember 110 at regular (or irregular) intervals and fastened to the firststitch member to provide a stitching, for example, as seen in theillustrations. The first and second stitch members may be made of amaterial comprising, for example, natural fibers (such as, e.g., manilahemp, hemp, linen, cotton, coir, jute, sisal, silk, wool, or the like)or synthetic fibers (such as, nylon, rayon, polypropylene, polyesters,polyethylene, aramids, polyaramids, or the like). The first and secondstitch members may each be braided.

FIGS. 5-7 show various steps of a process for manufacturing a footwearassembly comprising a footwear device 100 according to the presentdisclosure.

Referring to FIG. 5, after a footwear device 100 has been selected andcut (or made) to a size that fits a lower portion 200, an adhesive(e.g., a glue, rubber cement, polychloroprene-based adhesives, solventbased polyurethanes, polyurethane dispersions, copolyamide or ethylenevinyl acetate (EVA) hot melts, reactive hot melt urethanes, or the like)may be applied to a portion or the entire surface of the wall 150 of thefootwear device 100 (shown in FIGS. 1-2).

Referring to FIG. 6, the adhesive may be applied to a portion of or theentire surface of the interface section 220 of the lower portion 200(shown in FIG. 3). The interface section 220 and the wall 150 may beconfigured to substantially seamlessly mate with each other. Theadhesive may be applied to the interface section 220 at the same timethat the adhesive is applied to the wall 150, or it may be applied at adifferent time (e.g., before or after).

Referring to FIG. 7, after the adhesive is applied to the surface 150and the interface section 220, the surface 150 may be aligned with andaffixed to the interface section 220 around the entire perimeter of thelower portion 200 (shown in FIG. 3). A section of the upper portion (notshown) may also be treated with the adhesive and affixed to, forexample, the wall 140 (shown in FIGS. 1-2), so as to assemble thefootwear assembly. The wall 140 may be configured to mate with thetreated section of the upper portion.

FIG. 8 shows an example of a footwear assembly (i.e., a sneaker) thatcomprises a footwear device according to the instant disclosure. Otherfootwear assemblies besides sneakers are contemplated by the instantdisclosure. For example, the footwear assembly may be a shoe, a boot, aslipper, a dress shoe, a dance shoe, a sandal, a pump, an athletic shoe,and the like. The footwear assembly comprises an upper portion, thelower portion 200, and the footwear device 100.

While the disclosure has been described in terms of exemplaryembodiments, those skilled in the art will recognize that the disclosurecan be practiced with modifications in the spirit and scope of theappended claims. These examples are merely illustrative and are notmeant to be an exhaustive list of all possible designs, embodiments,applications or modifications of the disclosure.

What is claimed:
 1. A footwear device comprising: a longitudinal membercomprising: a substantially curved wall; and a first substantiallyplanar wall, wherein the substantially curved wall and the firstsubstantially planar wall form at least a portion of an outer boundaryof the longitudinal member.
 2. The footwear device of claim 1, furthercomprising a second substantially planar wall.
 3. The footwear device ofclaim 2, wherein the substantially curved wall, the first substantiallyplanar wall, and the second substantially planar wall form at least aportion of an outer boundary of the longitudinal member.
 4. The footweardevice of claim 1, further comprising a first stitch member that isconfigured to extend longitudinally along the longitudinal member of thefootwear device.
 5. The footwear device of claim 4, wherein the firststitch member comprises either a natural fiber material or a syntheticfiber material.
 6. The footwear device of claim 4, further comprising asecond stitch member that is configured to extend longitudinally alongthe longitudinal member of the footwear device.
 7. The footwear deviceof claim 6, wherein the second stitch member fastens the first stitchmember to the longitudinal member.
 8. The footwear device of claim 1,further comprising a material that is selected from the group consistingof: rubber, synthetic rubber, silicone, metal silicone, leather,plastic, a textile, a plaiting material, neoprene, wood, cork, andrubber.
 9. A footwear assembly comprising the footwear device accordingto claim
 1. 10. The footwear assembly of claim 9, further comprising: anupper portion; and a lower portion, wherein an interface section of thelower portion is affixed to a first surface of the first substantiallyplanar wall of the longitudinal member arid a section of the upperportion is affixed to a first surface of the substantially curved wallof the longitudinal member.
 11. The footwear assembly of claim 10,wherein the footwear assembly is selected from the group consisting of:a shoe, a boot, a slipper, a dress shoe, a dance shoe, a sandal, a pump,and an athletic shoe.
 12. The footwear assembly of claim 10, wherein theinterface section of the lower portion is affixed to the first surfaceof the first substantially planar wall of the longitudinal member withan adhesive selected from the group consisting of: glues, rubbercements, polychloroprene-based adhesives, solvent based polyurethanes,polyurethane dispersions, copolyamide or ethylene vinyl acetate hotmelts, and reactive hot melt urethanes.
 13. The footwear assembly ofclaim 10, wherein the section of the upper portion is affixed to thefirst surface of the substantially curved wall of the longitudinalmember with an adhesive selected from the group consisting of: glues,rubber cements, polychloroprene-based adhesives, solvent basedpolyurethanes, polyurethane dispersions, copolyamide or ethylene vinylacetate hot melts, and reactive hot melt urethanes.
 14. A method ofmaking a footwear assembly, comprising: providing a footwear devicecomprising a longitudinal member that comprises: a substantially curvedwall; and a first substantially planar wall, wherein the substantiallycurved wall and the first substantially planar wall form at least aportion of an outer boundary of the longitudinal member; providing anupper portion; providing a lower portion; affixing an interface sectionof the lower portion to a surface of the first substantially planar wallof the longitudinal member; and affixing a section of the upper portionto a surface of the substantially curved wall of the longitudinalmember.
 15. The method of claim 14, wherein the method further comprisesat least one of: applying an adhesive to at least one of the interfacesection of the lower portion of the footwear assembly and the surface ofthe first substantially planar wall of the longitudinal member beforeaffixing the interface section of the lower portion to the surface ofthe first substantially planar wall; and applying an adhesive to atleast one of the section of the upper portion of the footwear assemblyand the surface of the substantially curved wall of the longitudinalmember before affixing the section of the upper portion to the surfaceof the substantially curved wall.
 16. The method of claim 15, whereinthe adhesive is applied to both the interface section of the lowerportion and the surface of the first substantially planar wall of thelongitudinal member.
 17. The method of claim 15, wherein the adhesive isapplied to both the section of the upper portion and the surface of thesubstantially curved wall of the longitudinal member.
 18. The method ofclaim 15, wherein the interface section of the lower portion is affixedto the surface of the first substantially planar wall of thelongitudinal member with an adhesive selected from the group consistingof glues, rubber cements, polychloroprene-based adhesives, solvent basedpolyurethanes, polyurethane dispersions, copolyamide or ethylene vinylacetate hot melts, and reactive hot melt urethanes.
 19. The method ofclaim 15, wherein the section of the upper portion is affixed to thesurface of the substantially curved wall of the longitudinal member withan adhesive selected from the group consisting of glues, rubber cements,polychloroprene-based adhesives, solvent based polyurethanes,polyurethane dispersions, copolyamide or ethylene vinyl acetate hotmelts, and reactive hot melt urethanes.